About Rourkela Steel Plant

Rourkela Steel Plant (RSP), the first integrated steel plant in the public sector in India, was set up with German collaboration with an installed capacity of 1 million tonnes. Subsequently, its capacity was enhanced to 2 million tonnes of hot metal, 1.9 million tonnes of crude steel and 1.67 million tonnes of saleable steel. After implementing a massive modernisation and expansion that is in the last leg of completion, Rourkela Steel Plant has enhanced its capacity to 4.5 million tonnes of Hot Metal and 4.2 Million Tonnes of Crude Steel.

Production capacity (In Million Tonnes Per Annum)

  Pre-Expansion Post-Expansion
Hot Metal 2 4.5
Crude Steel 1.9 4.2
Saleable Steel 1.67 3.9

RSP was the first plant in India to incorporate LD technology of steel making. It is also the first steel plant in SAIL and the only one presently where 100% of slabs are produced through the cost-effective and quality-centric continuous casting route. It is SAIL’s only plant that produce silicon steels for the power sector and high quality pipes for the oil & gas sector.. Its wide and sophisticated product range includes various flat, tubular and coated products.

Details of Modernisation and Expansion of RSP (Please click link for details)

Rourkela Steel Plant

Modernisation and Expansion of Rourkela Steel Plant

Rourkela Steel Plant is on the verge of completing a massive modernization and expansion programme that is truly historic. With this the Steel Plant has doubled its capacity and augmented it to the level of 4.5 MTPA (Million Tonne per Annum) of Hot Metal from the previous level of 2 MTPA. The Crude Steel making capacity has simultaneously increased from the level of 1.9 MTPA to 4.2 MTPA and production of Saleable Steel is all set to zoom from the level of 1.671 MTPA to 3.99 MTPA.

It is worth mentioning here that, apart from increasing the volume the other benefits envisaged from this phase of modernisation and expansion are increased economy of scale, enlarged customer base, enhanced quality, reduced cost of production, better market compatibility, improved labour productivity, stricter adherence to environment norms and superior Techno-economics.

Some key new units are:

RAW MATERIAL HANDLING FACILITIES:
Post expansion, the new raw material requirement of RSP has to go upto about 12 MTPA from the previous requirement of 5 MTPA. The augmentation facilities that have been added include:

  • Receiving, unloading, reclaiming and finally transporting of raw materials required for Blast Furnce-5
  • Base mix preparation for the New Sintering Complex
  • Transportation of Flue dust, Mill scale etc.
  • Transportation of crushed fuel and flux for trimming addition to the new Sinter Unit
  • Conveyor line for transportation of Calcining Plant grade limestone and dolomite to consuming units
  • Automatic sampling system

Facilities / Equipment in New OBBP:

  •  Unloading :
    •  Wagon Tippler: 1 No.
    •  Track hopper: 1 No.
  •  Stacking & Reclaiming :
    •  4 No of Beds to stack the incoming raw materials
    •  2 No. of Beds for Base-mix
  •  Equipments in the Beds
    • Twin Boom Stacker : 2 No.
    • Stacker cum Reclaimer : 1 No.
    • Barrel Reclaimer : 4 Nos.
    • Bucket wheel Reclaimer: 1 No.
  • Other equipments:
    • Flux Crushers : 8 Nos.
    • Coke crushers : 12 Nos

COKE OVEN BATTERY # 6:

The battery is top charged, compound twin flue, under jet, regenerative heating with partial recirculation of waste gases. The 7 metre tall battery of 67 ovens has been installed to produce run of oven Coke (Dry) of 0.768 MT/Year. The Computerized Heating Control System (COHC) has been installed for the battery operation for the process management system to improve reduction in environmental emission, improve coke quality & productivity. A coal tower of 4000-ton useful capacity for storing coal, Leak Proof Doors, Water Sealed AP Covers, HPLA (High Pressure Ammonical Liquor Aspiration), Door & Frame cleaner, High Pressure Water Jet door cleaner, Land based Pushing Emission Control (PEC) System and Effluent Disposal and Coke Dry Cooling Plant (CDCP) have been provided for efficient environment management.

Some important components of the package are:

New Coke Dry Cooling Plant

The principle of coke dry quenching is based on cooling of hot coke with inert gas circulating in close loop between the chamber of hot coke and the waste heat Boiler. Apart from ensuring environment friendly operation, the CDCP is also designed to enhance the coke quality.

Technological Parameters/Features of CDCP
Temperature of coke charged in the chamber : 1050°C
Temperature of coke after cooling :  < 200°C
Time of coke cooling in chamber : 2.0-2.5 Hr.
Temp. of circulating gas before cooling chamber : 170-180°C
Temp. of circulating gas before waste heat boiler :  750-800°C
Pressure of steam generated : 66 ata
Temperature of steam generated : 500°C
Generation of steam / boiler :  25 ton / Hr

New Coal Handling Plant

The new Coal Handling Plant can hold 15 days stock of Coking Coal for COB #6 (@ 3500 T/day) and CDI Coal of 10 days stock @ 1500 T/day). There are 24 Nos. of RCC silos for stocking of Coking Coal and for CDI Coal, 6 Nos of RCC silos, each of capacity 2500 Tons.

New Coal Chemical Department

The new CCD has been installed to process coke oven gas generated from the new Coke Oven Battery # 6. This cleans the raw coke oven gas by removing Tar, Ammonia, Hydrogen, Sulphur, Sulphide and Naphthalene. The coke oven gas is being cooled finally to 3000 C at the outlet of final gas cooler. There are Naphthalene Washer and Benzole Scrubber to have clean coke oven gas for use of the Plant.

SINTERING UNIT # 3

The new single strand Sinter Unit has an effective suction area of 360 m³ and an annual production capacity of 3.70 MT of gross sinter with sinter productivity of 1.3 T/m² /hr. The output stack emission is less than 50 mg/Nm³, by making the unit an environment friendly unit. The sintering Unit is being provided with Eirich type mixer and noduliser instead of the conventional mixing & balling drum. A circular cooler has been installed for sinter cooling. Another new feature is pneumatic conveying of ESP dust, as a part of which the ESP dust will be charged to the sinter raw mix bed after passing through an Eirich type Granulator. The Eirich type Mixer, Noduliser & Granulator have been installed for the first time in SAIL Plants.

Technical Details of SP-3
Sintering area : 360 Sq meter
Spec. Productivity : 1.3 T/m²/hr
Under grate suction : 1650 mmWC
Circular annular dip rail deep bed type sinter cooler : 396 Sq meter
Tumbler Index : +6.3 mm 75% Min.
RDI : 30% max
Rated Capacity of incoming raw material : 1500 tph
Rated Capacity of outgoing sinter : 550 tph

BLAST FURNACE # 5

One of the biggest Blast Furnaces of the country, the new Blast Furnace # 5 with a useful volume of 4060 Cubic metres is designed for a production capacity of 2.8 MTPA with a daily hot metal production of 7924 T (avg.). The Furnace operates at high intensification level and for a campaign life of 20 years. Equipped with modern features such as pulverized coal injection system, cast house fume extraction system, cast house slag granulation system, top gas recovery turbines of 14 MW capacity, Twin material bin BLT system, Waste Heat Recovery System, Plate/Stave Coolers and Conveyor Belt Charging System, this Blast Furnace has Level II Automation.

Technical details and operating parameters of BF#5:

Item Unit Values
Working volume 3470
Useful volume 4060
Hearth Diameter m 13.2
No. of Tuyers Number 36
Coke rate (Incl. -20 Kg Nut Coke 8-34 mm) Kg/THM 360
Coal dust (CDI coal) Kg/THM 150 (avg.) ; 200 (Design)
Blast volume N m³/min 6125
Blast Temperature OC 1200 OC (avg.); 1250 OC (max)
Blast Oxygen Enrichment % 4 – 6
BF Top gas volume (Net & dry) N m³/THM 1500 – 1550
BF Top Pressure Kg/c m² (g) 2.5 Max.
Slag Rate Kg/THM 290 - 310

The furnace has twin flat cast house with four tap holes. Auxiliaries of BF#5:

Turbo Blower Station

The 3 Turbo Blowers along with its all auxiliaries provides cold blast to the stoves of new BF # 5.

Boiler, STG, BPTG & Blowing Station

The unit comprising 3 Boiler arrangements, 2 Steam Turbo Generators and 1 Back Pressure Turbo Generator generates power as well as cold blast to feed the Blast Furnace and the stoves.

Torpedo Ladles & Repair Shop

The 10 Torpedo Ladles with features like higher capacity and lesser scope of hot metal temperature loss are being used for transferring hot metal from the new Blast Furnace #5 to Steel Melting Shop or Pig Casting Machine. It is noteworthy that, these torpedoes are being used for the first time in SAIL. The Torpedo Ladle Repair Shop handles jobs like refractory lining, ladle inspection, ladle heating and cooling.

Pig Casting Machine

The twin strand 1500 TPD capacity Pig Casting Machine has average strand speed 9 m/min.

AUGMENTATION OF SMS-II

3rd BOF Converter (1 X 150 T)

The new top blown Basic Oxygen Furnace (3rd converter of SMS-II) of capacity 1.584 MT Liquid steel per year is designed with provision for adoption of combined Oxygen blowing from top and inert gas stirring (with Argon and Nitrogen) from bottom.

The new RHOB is also a first time feature of RSP that helps in producing higher strength and high quality special grade steel

Major design features of 3rd BOF Converter
Nominal heat size : 150 t
Maximum heat size : 165 t
Working volume with new lining : 165 m3
Tap to Tap time : 45 Min.
Oxygen Flow Rate : 500 NM3 /Min. (avg.)
Tilting Angle : 3600
Tilting speed : 0.1 – 1.0 rpm
Number of Heats per day : 32 (avg.)

Slab Caster # 3 - Conventional (1 x 1 Strand)

With a capacity to produce slabs with width upto 2500 mm which makes it one of the widest in the country, the main objective of the New Slab Caster-3 is to make slabs for the 4.3 metre wide New Plate Mill. It can handle slab tonnage up to 30 tonnes, while the old casters have the capacity of 16 to17 tonnes. Built with latest design and state-of-the-art technology the Caster is equipped with modern features such as ladle to tundish slag detection system, vertical high speed mould with automatic width adjustment, hydraulic mould oscillator, automatic mould level controller, break-out prediction system, air mist spray cooling system, dynamic spray cooling system, continuous straightening, automatic torch cutting machine, slab pusher cum piler arrangement, transverse torch cutting machines and computerized process control system (Level II) to name a few.

New Plate Mill

The new 4.3 metre wide Plate Mill has been installed having initial capacity of 1.0 MT (0.92 MT saleable), which can be augmented to a capacity of 1.8 MT (1.674 MT saleable). The Plate Mill equipped with state-of-art technology produces wide range of plates with close tolerances to meet stringent international standards. The 4-Hi reversing mill is designed for roll force up to 90 MN, with hydraulic automatic gauge control, roll bending and shifting facilities and provision of on-line thickness, profile and width measurement.

The Plate Mill has advanced computerized control system for Plan View Rolling (PVR) process to maximize yield and an automated accelerated cooling system to produce high strength TMCP rolled plates including for pipe grades upto API XL 100 with lower cost. The mill is designed with High capacity levelers with hydraulic control and under load positioning system, high capacity double side Trimming and Cross-cut-shears up 50 mm capacity to produce distortion free plates. For operation with a lean manpower and to avoid loss of material identity throughout the production process, the Plate Mill will be equipped with online ultrasonic testing facility and advanced control systems and material tracking facilities.

Input Slab Output
Width = 1200 to 2400 mm As Rolled Plate Length = 42 mtr maximum
Length = 2200 to 4100 mm Finished Plate Thickness = 6 to 100 mm
Thickness = 210 to 300mm Width = 1500 to 4100 mm
Length = 6000 to 15000 mm
Sheared plate thickness= 6mm-50 mm
Cold levelling of plates = 40mm Max.
Special quality plates: API upto X-100, HSLA, Micro alloy Structural

Location

Rourkela Steel Plant is located in the north-western tip of Odisha and at the heart of a rich mineral belt. Being situated on the Howrah-Mumbai rail mainline, Rourkela is very well connected with most of the important cities of India. The nearby airports are Ranchi (173 km), Bhubaneswar (378 km) and Kolkata (413 km). Rourkela also has an airstrip maintained by RSP.

Contact Us

Ramendra Kumar
DGM (PR) & CoC
Rourkela Steel Plant
Rourkela-769011,Odisha
Email : rsp.coc@gmail.com
Tel : 91 - 0661- 2510050

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